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Summary of Contents for Global MX PrimeGen
- Page 1 5024343 CONFORMS TO ANSI/CAN/UL/ULC STD 2200 MX PrimeGen Power Generator NSTALLATION PERATION AND AINTENANCE ANUAL Global Power Technologies www.globalte.com...
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Page 3: Table Of Contents
Table of Contents COPYRIGHT, LIABILITY, AND CONTACT INFORMATION ............1 IMPORTANT SAFETY INSTRUCTIONS ..................2 MANUAL ICONS AND SAFETY BANNERS ..................4 TECHNICALLY QUALIFIED PERSONNEL ..................4 BATTERY SAFETY ......................... 4 START-STOP OPERATIONS ......................5 PRODUCT INFORMATION ...................... 6 TERMS AND ACRONYMS ......................7 DATA PLATE .......................... - Page 4 REMOTE MONITORING ......................32 REMOTE MONITORING THROUGH DRY CONTACTS (SCADA) ............ 32 REMOTE MONITORING THROUGH MODBUS ................33 REMOTE MONITORING THROUGH IOT ..................36 7.3.1 LOG-IN INSTRUCTIONS ......................36 SHUTDOWN ......................... 39 SHUTDOWN ..........................39 EMERGENCY SHUTDOWN (ESD) ....................39 SERVICE AND MAINTENANCE....................
- Page 5 EMISSION-RELATED WARRANTY ..................62 14.1 WARRANTY PERIOD ........................62 14.2 COMPONENTS COVERED ......................62 14.3 LIMITED APPLICABILITY ......................63 14.4 WARRANTY CLAIMS ........................63 APPENDIX A — PRODUCT SPECIFICATIONS ..................64 APPENDIX B — WEIGHT AND DIMENSIONS ..................65 Table of Figures Figure 3-1 –...
- Page 6 List of Tables Table 1 – MX Power Generator Fuel Specifications ................11 Table 2 – Customer Wiring Connections (Single Phase Systems) ............19 Table 3 – Customer Wiring Connections (3 Phase Systems) ..............20 Table 4 – MX Modbus Configuration Settings ..................33 Table 5 –...
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Page 7: Copyright, Liability, And Contact Information
Canada T2C 5K7 Customer Service/Technical Support: 1-403-720-1190 Copyright © 2022 by Global Power Technologies (GPT). All rights reserved. No part of this manual may be reproduced without permission in writing from GPT, except by a reviewer who may quote brief passages or reproduce illustrations in a review Copyright with appropriate credit;... -
Page 8: Important Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions for the MX PrimeGen Power Generator that should be followed during installation and maintenance of the generator and its batteries. Read the following safety warnings before beginning assembly, installation, or maintenance of the MX Power Generator. - Page 9 27. Do not exceed the fuel pressure stamped on the MX Power Generator’s data plate without factory approval. 28. The MX Power Generator exhaust can be very hot. Do not touch any of the exhaust components or bring exposed skin near hot exhaust gases. 302672 Rev2 | MX PrimeGen...
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Page 10: Manual Icons And Safety Banners
2. When replacing batteries, use the same number and the following type batteries: Type 31 AGM batteries, 12V, 100-105 Ah. Do not dispose of battery or batteries in a fire. The battery is capable of exploding. CAUTION! 302672 Rev2 | MX PrimeGen... -
Page 11: Start-Stop Operations
2. A manual shut-off valve must be installed according to local standards at the fuel inlet to allow fuel supply to be cut off in the event of any problems. Refer to Section 4.4.3 for details. 302672 Rev2 | MX PrimeGen... -
Page 12: Product Information
Engine starting range with Cold Ambient configuration (“-CA”) is -40°C Emergency Shutdown (ESD) to +40°C (120V external power is recommended for engine startup below -5°C) LED Display Shows system status, alarms, runtime, etc. Refer to Section 5.2 302672 Rev2 | MX PrimeGen... -
Page 13: Terms And Acronyms
Programmable Logic Controller (also dubbed System Controller) Printed Circuit Board SCADA Supervisory Control and Data Acquisition Engine Control Unit Internet of things The following symbols are used in this manual and on labels on the MX PrimeGen units: or Φ Alternating Phase Equipment Current... -
Page 14: Data Plate
Nominal power output of the MX unit at 40°C (104°F) Max Unbalanced Load Maximum unbalanced load Model Number Model number of the MX unit (Refer to Model Tree in Figure 3-2) Serial Number The unique number assigned to the MX unit for traceability. 302672 Rev2 | MX PrimeGen... -
Page 15: Assembly And Installation
The MX Power Generator must be installed so that access is restricted to only qualified service personnel who have been instructed of the reasons for the restrictions applied to the location and about any precautions that must be taken when accessing the unit. 302672 Rev2 | MX PrimeGen... -
Page 16: Fuel Supply
3. Fuel supply pressure never exceeds 5 psi (34.5 kPa 4.1.3 STANDARD SPECIFICATIONS FOR GASEOUS FUEL Global Power Technologies’ MX Power Generator can run on natural gas or propane depending on the model type. Natural gas fuel systems: 1. Shall have a Methane number greater than 50. -
Page 17: Unpacking And Lifting
Report any damage to GPT as soon as possible. Use a hoist system, with spreader bar and chains, to lift the MX Power Generator into place. The hoist system design and spreader bars are not provided by GPT. 302672 Rev2 | MX PrimeGen... -
Page 18: Figure 4-2 - Slinging And Lifting Diagram
WARNING! Figure 4-3 – Lifting with Forklift The MX Power System can also be lifted using a forklift from either the front or rear side using the spaces provided in the base of the unit. 302672 Rev2 | MX PrimeGen... -
Page 19: Access Panels
4. Gently lower the panel down to the ground and move it out of the way. Be careful when removing the panels. Grip both handles firmly. The removable side panels weigh approximately 45 lb. (20.4 kg). CAUTION! 302672 Rev2 | MX PrimeGen... -
Page 20: Assembly And Installation
4 — 1/2-20 10" threaded rods 4 — 1/4-20 nuts 6 — 1/4 lock washers 6 — 1/4 0.625 flat washers 2 — 1/2-20 x 0.625 hex screws *Battery cables may be shipped with the battery terminal boots disconnected. 302672 Rev2 | MX PrimeGen... -
Page 21: Batteries
4. Terminate wires 221, 222 and 223 on the negative terminal of the second battery. 5. If your MX unit was shipped with the battery terminal boots disconnected, connect them by sliding the covers into the battery cables then fit the installed terminal boots over the battery stud terminal. 302672 Rev2 | MX PrimeGen... -
Page 22: Radiator Glycol
Radiator coolant mixtures for the MX Power Generator are as follows: • 60/40 ethylene glycol/water mixture can be used for all MX units. • 50/50 ethylene glycol/water can be used for MX units in warmer ambient climates that remain above -5°C (23°F). 302672 Rev2 | MX PrimeGen... -
Page 23: Fuel Supply
Table 2 and Table 3 list the locations of the Remote Start and common alarm terminal blocks. Add a soft starting mechanism such as a VFD for any motor loads that are above NOTE: 1kW. Power factor must be considered when calculating motor loads. 302672 Rev2 | MX PrimeGen... -
Page 24: Figure 4-9 - Holes For Customer Connections
Class 1 wiring methods are to be used for field wiring connections to terminals of a Class 2 circuit. Use copper wire rated to a minimum of 60°C or 75°C CAUTION! only. Figure 4-10 – Customer Wiring Terminations (Single Phase Systems) 302672 Rev2 | MX PrimeGen... -
Page 25: Figure 4-11 - Customer Terminations (3 Phase Systems)
Refer to Section 7.1 for operational instructions of all SCADA dry contacts on terminal block X6. Figure 4-11 – Customer Terminations (3 Phase Systems) Ensure that the correct polarity is followed. Incorrect polarity may cause damage to the generator or customer equipment. WARNING! 302672 Rev2 | MX PrimeGen... -
Page 26: Wind Shield Adjustment
• Wait 15 to 30 minutes to allow the system to stabilize between wind shield panel position adjustments. During shipping, the wind shield may be removed or adjusted to a smaller gap. NOTE: Ensure that wind shield is installed with the correct gap before running the unit. 302672 Rev2 | MX PrimeGen... -
Page 27: Start-Up
This minimizes thermal load on the engine and helps maintain stability of the synchronous alternator. CAUTION! 11. If the receptacle plug will be used, turn on the receptacle breaker (Q8) located inside the electrical panel. 302672 Rev2 | MX PrimeGen... -
Page 28: External Battery Charge And Cold Ambient Start
120V AC plug located in the engine room. Connect the plug to an external AC power source that can handle up to 1.5 kW load. Figure 5-5 – Main System and Battery Charge Breaker (3 Phase) 302672 Rev2 | MX PrimeGen... -
Page 29: Remote Start-Up
2. Start the MX Engine by sending a signal to the “Remote Start/Stop” dry contacts (X6.11/X6.12). These contacts must be kept shorted together to keep the engine running. Refer to Section 4.4.4 for SCADA wiring connections, and Section 7.1 for detailed information on each SCADA dry contact. 302672 Rev2 | MX PrimeGen... -
Page 30: Operation
• The MX System will shut down the system completely if the local ESD button is pressed, or a signal is sent to the External ESD dry contact. • Remote operation is disabled; the MX System will ignore any incoming Remote Start/Stop commands. SCADA outputs will still function normally. 302672 Rev2 | MX PrimeGen... -
Page 31: Auto/Man Switch - Auto-Standby / Manual Modes
MX will automatically crank and start the engine when it detects fuel pressure again Standard engine stops are performed more slowly in Auto-Standby Mode. Expect at NOTE: least 30 seconds of engine idling before full engine shutoff occurs. 302672 Rev2 | MX PrimeGen... -
Page 32: Local On/Off
The display is activated by pressing the button labelled “SCREEN”, beside or above the LCD screen, as shown in the photos below. Figure 6-2 – Alternate Pump Button Location 302672 Rev2 | MX PrimeGen... -
Page 33: Display Screens
Line 2 – Generator engine start timestamp: Date (yyyymmdd), and Time (24hr, UTC) Line 3 – Current Local/Remote Mode setting (set by LOC/REM switch) Line 4 – Current Auto/Manual Mode setting (set by AUTO/MAN switch) 302672 Rev2 | MX PrimeGen... - Page 34 Line 4 – Shows the currently estimated flow rate of propane, in L/Day Estimated parameters for both natural gas and propane are provided. Refer only to NOTE: the parameter that matches your MX Power Generator’s equipped fuel type. 302672 Rev2 | MX PrimeGen...
- Page 35 Line 1 – Alternator L1 Power Factor, and L1-L2 Phase Voltage (V) Line 2 – Alternator L2 Power Factor, and L2-L3 Phase Voltage (V) Line 3 – Alternator L3 Power Factor, and L3-L1 Phase Voltage (V) Line 4 – Alternator Overall System Power Factor 302672 Rev2 | MX PrimeGen...
- Page 36 Line 2 – The radiator Coolant Pump speed is shown in RPM. Line 3 – Engine throttle percentage is shown, and air-fuel ratio (Lambda) is also shown. Line 4 – Fuel Pressure Switch status is shown. “YES” if fuel is available, “NO” otherwise. 302672 Rev2 | MX PrimeGen...
- Page 37 Line 2 – Coolant Pump control voltage (V) is displayed, and PLC System Controller Status (Hex). Line 3 – Radiator Fan control voltage (V) is displayed, and PLC Discrete Input Status (Hex). Line 4 – Engine Room Fan control voltage (V) is displayed, and PLC Discrete Output Status (Hex). 302672 Rev2 | MX PrimeGen...
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Page 38: Remote Monitoring
Level 4 Alarm and shut down the engine. If continuity across these terminals is restored, the Level 1 Alarm will automatically clear, but the Level 4 Alarm (if triggered) will stay active. Refer to Section 12.1 for more details on MX Alarms. 302672 Rev2 | MX PrimeGen... -
Page 39: Remote Monitoring Through Modbus
The spare LAN port on the MX Modem should RS-485 T/R– will be terminal X6.17. be used for Modbus TCP/IP communications. The MX Power Generator cannot be controlled through Modbus. NOTE: Modbus support is for diagnostics and system information only. 302672 Rev2 | MX PrimeGen... -
Page 40: Table 5 - Mx Generator Modbus Map
Actual Engine Coolant Outlet Temperature float °C 40048 - 40049 Actual Engine Coolant Inlet Temperature float °C 40050 - 40051 Radiator Fans Control Voltage float 40052 - 40053 Enclosure Fans Control Voltage float 40054 - 40055 302672 Rev2 | MX PrimeGen... - Page 41 40112 - 40113 Alternator L3 (W) AC Active (Real) Power float 40114 - 40115 Alternator L1 (U) AC Apparent Power float 40116 - 40117 Alternator L2 (V) AC Apparent Power float 40118 - 40119 302672 Rev2 | MX PrimeGen...
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Page 42: Remote Monitoring Through Iot
Please contact GPT to request access to your MX Power Generator’s IoT web portal. We will require your organization (company) name, as well as the user email addresses for each user who requires access. These user email addresses should be the same as used for their Microsoft Accounts. 302672 Rev2 | MX PrimeGen... -
Page 43: Figure 7-2 - Log-In Page For Remote Monitoring System
30 minutes. 5. Raw Data — Raw data feed from the MX Generator, with timestamps. This will show telemetry packets, as well as cellular connections/disconnections from IoT Central. 6. Mapped Aliases — Unused. (Blank screen) 302672 Rev2 | MX PrimeGen... -
Page 44: Figure 7-3 - Remote Monitoring System Dashboard
Global Power Technologies REMOTE MONITORING Figure 7-3 – Remote Monitoring System Dashboard 302672 Rev2 | MX PrimeGen... -
Page 45: Shutdown
The MX Power Generator is equipped with an emergency shutdown system. Pushing the ESD button on the electrical panel door will accomplish the following: 1. Stops the generator. 2. Cuts power to MX unit and the customer load. 3. Cuts power to the system controller. 302672 Rev2 | MX PrimeGen... - Page 46 Shutdown of the system. This ESD will function the same as the ESD button, but remotely. The ESD dry contact is a normally-closed contact. To use external SCADA controls, remove the factory-provided jumper. Otherwise, the jumper must remain in place. CAUTION! 302672 Rev2 | MX PrimeGen...
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Page 47: Service And Maintenance
A maintenance Log is available at the end of this manual. Record maintenance activities and any important notes on this log. Perform a leak check on the fuel line periodically and at each maintenance visit. 302672 Rev2 | MX PrimeGen... -
Page 48: Standby Oil Systems
We recommend that taking periodic oil samples and getting them NOTE: analyzed to verify validity of the recommended service intervals for your application. 302672 Rev2 | MX PrimeGen... -
Page 49: Systems With Extended Oil Reservoir
NOTE: and more. We recommend taking periodic oil samples and getting them analyzed to verify validity of the recommended service intervals for your application. 302672 Rev2 | MX PrimeGen... -
Page 50: System Check
1/2-inch Swagelok connection where a manual shut-off valve must be installed for gas shut-off to the engine. Check the fuel lines for leaks periodically and during each scheduled maintenance. 302672 Rev2 | MX PrimeGen... -
Page 51: Air System Filters Check
5. Within the primary air filter is the secondary safety radial seal air filter. If the engine run time has exceeded 27,000 hours, then this safety radial seal air filter (GPT Part number 302757) must be replaced. For detailed service and maintenance instructions please refer to the MX Service Manual (303453). 302672 Rev2 | MX PrimeGen... -
Page 52: Battery Inspection
For detailed service and maintenance instructions or battery replacement instructions please refer to the MX Service Manual (303453). To avoid overtightening, do not use tools when tightening the battery clamp wing nut. Keep them hand tight. CAUTION! 302672 Rev2 | MX PrimeGen... -
Page 53: Oil System Check
Do not dispose of battery or batteries in a fire. The battery is capable of exploding. Do not open or mutilate the batteries. Released electrolyte has been known to be harmful to the skin and eyes and to be toxic. WARNING! OIL SYSTEM CHECK Figure 9-4 – Standby Oil Configuration 302672 Rev2 | MX PrimeGen... -
Page 54: Check Oil Catch Can
Wait approximately 20 minutes for the oil to cool before changing, though if the oil gets too cold may take a long time to drain. For detailed service and maintenance instructions on performing a full oil change, please refer to the MX Service Manual (303453). 302672 Rev2 | MX PrimeGen... -
Page 55: Coolant System Check
Close the tank. 9.10 COOLANT CHANGES Every 16,000 hours the coolant should be fully flushed, and the coolant pump replaced. For detailed service and maintenance instructions on coolant changes please refer to the MX Service Manual (303453). 302672 Rev2 | MX PrimeGen... -
Page 56: O2 Sensor Replacement
The engine, cylinder head, and/or oil pump will need to be replaced or repaired after 27,000 to 60,000 hours. This can be determined based on history of engine loading, cylinder compression checks, and overall engine performance. 302672 Rev2 | MX PrimeGen... -
Page 57: Storage
An AC plug is provided to allow external AC to power the internal MX Battery Charger. If charging these batteries outside of an MX System, the operator should float-charge each 12V battery at a voltage of 13.8V at 25°C (77°F). 302672 Rev2 | MX PrimeGen... -
Page 58: Maintenance And Commissioning Spares
Standby Run, 27,000 Hours 303045 COOLANT, 1 GAL, 60/40 EG, YELLOW VCS 302737 COIL ASSY, IGNITION 302736 CORD SET, RESISTIVE, SPARK PLUG 302757 AIR FILTER, SAFETY RADIAL SEAL 303117 GASKET, CYLINDER HEAD COVER 302745 WASHER, SEAL, VALVE COVER 302672 Rev2 | MX PrimeGen... -
Page 59: Extended Run Oil Capacity Systems
Extended Run, 27,000 Hours 303045 COOLANT, 1 GAL, 60/40 EG, YELLOW VCS 302737 COIL ASSY, IGNITION 302736 CORD SET, RESISTIVE, SPARK PLUG 302757 AIR FILTER, SAFETY RADIAL SEAL 303117 GASKET, CYLINDER HEAD COVER 302745 WASHER, SEAL, VALVE COVER 302672 Rev2 | MX PrimeGen... -
Page 60: Commissioning And Recommended Spares
To use the inverter, connect it to a vehicle battery using the attached jumper cables ensuring that the clamps’ connections are secure. If used in extreme cold temperatures below -35°C (-31°F), warm-up the inverter inside a vehicle before operating. Contact GPT to order. 302672 Rev2 | MX PrimeGen... -
Page 61: Troubleshooting
Engine room temperature is low, and the engine may not be able Temperature Low to start successfully. Engine room enclosure temperature is too high. Engine Room This can indicate severe ambient conditions, engine overload, or Temperature High engine room air-fan failures. 302672 Rev2 | MX PrimeGen... - Page 62 Communication Error errors can indicate power meter failure or wire failure ECU Communication Communications to the Engine Control Unit have failed. This can Error indicate issues with the engine wire harness, or ECU failure. 302672 Rev2 | MX PrimeGen...
- Page 63 Replace the SD Card if alarm persists. One or more analog MX sensors are reading out-of-bounds, Sensor Failure indicating sensor failure. When seen with other alarms, this may be the cause of the other alarm code. Contact GPT for assistance 302672 Rev2 | MX PrimeGen...
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Page 64: Parts List
303115 HEAD ASSEMBLY, SHORT (W/O STUD), 1KS-CHP 303116 GASKET SET, CYLINDER HEAD EXCHANGE, 1KS-CHP 303117 GASKET, CYLINDER HEAD COVER, 1KS-CHP 302557 ELBOW, EXHAUST, 2", 90°, ALUMINIZED 302595 STRAIGHT, EXHAUST, 36”, ALUMINIZED 302709 RAIN CAP, EXHAUST, 302672 Rev2 | MX PrimeGen... - Page 65 HOSE, ASSEMBLY, FUEL GAS, 0.5MNPT, 28"LG 316SS 302758 CATALYST ASSEMBLY, EXHAUST, MX 302974 SILENCER, EXHAUST, 6X25, 2" EI/EO, BLK 51071 FUSE, 6A 250V, 5X20MM, GLASS 57485 FUSES, 15A 125V, 5X20MM, GLASS 301011 BATTERY CHARGER, 24V, 10A, UNIV AC 302672 Rev2 | MX PrimeGen...
- Page 66 RECTIFIER, 3 PH, 1.2KV, 60A, CRYDOM—For 3 Phase Systems Only 70487 RELAY, 12VDC, 6A SPDT 65548 RELAY, 24VDC, 6A SPDT 300841 RELAY, 24VDC, 8A DPDT 302657 RELAY, 24VDC, 30A SPST 302649 RELAY, 120VAC, 6A 4 CO 300843 RELAY, 120VAC, 6A SPDT 302672 Rev2 | MX PrimeGen...
- Page 67 54595 SWITCH, PUSH BUTTON, DPDT MOMENTARY 301881 SWITCH, SELECTOR, MAINTAINED, 22MM, BLK 303646 MX THERMAL CUTOFF ASSY 302797 PCB MODULE, FACE PLATE, VB-2100 W/ IO EXP 303638 PLC ASSY, MX PLC ASSY W/ SD CARD 302672 Rev2 | MX PrimeGen...
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Page 68: Emission-Related Warranty
EMISSION-RELATED WARRANTY 14 EMISSION-RELATED WARRANTY Global Power Technologies (GPT) warrants that the MX Power Generator, including all parts of its emission control system: 1. Is designed, built, and equipped so it conforms with the requirements of EPA CFR 40 Part 1054.120 at the time of sale, and... -
Page 69: Limited Applicability
Technologies have no responsibility, or by acts of God. This includes failures that have been directly caused by the operator’s abuse of the MX Power Generator or the operator’s use of the MX Power Generator in a manner for which it was not designed and are not attributable to Global Power Technologies in any way. -
Page 70: Appendix A - Product Specifications
For temperatures outside this For cold starting below -5°C, Cold Range range, please contact GPT Ambient configuration (-CA) will be required Humidity Range 0-100% RH Electrical Area General Non-Hazardous Classification Harmonic Distortion <5% Tested with linear load 302672 Rev2 | MX PrimeGen... -
Page 71: Appendix B - Weight And Dimensions
85 in (97 5/8 with rain cap) 216 cm (248 cm with rain cap) OVERALL WIDTH 80 1/4 to 90 1/4 in 204 cm to 229 cm OVERALL DEPTH 42 1/2 in 108 cm OVERALL APPROX. WEIGHT 1750 lb. 794 kg 302672 Rev2 | MX PrimeGen...